Method and filling element for the pressure-filling of containers with a liquid filling material

ABSTRACT

A method for filling containers with a filling material under pressure using a filling system comprising a filling element, which has a liquid channel having a liquid valve in a filling element housing, wherein the liquid channel is connected to a liquid chamber of a filling material vessel, which is partially filled with filling material and under pre-stress or filling pressure, upstream of the liquid valve in the flow direction of the filling material and forms at least one discharge opening downstream of the liquid valve in the flow direction of the filling material, at which discharge opening the particular container is arranged with a container opening in a sealed position at least during the filling process, and wherein a probe is arranged in a return gas pipe.

The invention relates to a method according to the preamble of claim 1 and to a filling element according to the preamble of claim 8 or 12 for filling bottles or similar containers with a liquid filling material.

Methods and filling elements/filling systems or filling machines for filling containers are known in different embodiments. In particular, for the pressure-filling of containers, methods that use a filling system, for example single-chamber filling system, are known in which during the filling phase of the filling process, when the liquid valve is opened the liquid filling material flows to the respective container which is arranged in sealed position against the filling element and pre-tensioned with an inert gas (CO2 gas) that is at filling pressure, and the inert gas that is thereby displaced from the container is returned, through a return gas tube which extends into the container during filling, as return gas into a gas space of a partially filled tank, said gas space being at the filling pressure, or into a channel carrying the inert gas at filling pressure. The flow of the liquid filling material to the container is ended by the return gas tube eventually becoming immersed beneath the surface of the filling material rising in the container and the filling material rising in the return gas tube until a state of equilibrium is reached between the level of the filling material surface in the tank and an equilibrium level of the filling material surface in the return gas tube. The liquid valve is not closed until at a predetermined point in time after this state of equilibrium is reached, i.e. with rotary-type filling machines, not until the filling element concerned has reached a predetermined angular position of the rotary motion of the rotor. The point in time and/or angular position of the rotor at which the liquid valve finally closes are selected so that when there is a plurality of filling elements the desired fill height is reliably reached even with the “slowest” of these filling elements, although the closing of the liquid valves of the filling elements could actually happen much earlier and so that the total duration of the particular filling process could be reduced and/or the output of the filling system or filling machine increased.

A pressure-filling system (DE 1607996) is known in which the particular filling element is executed with a probe which governs the fill height in the bottle and which during filling extends through the bottle mouth into the bottle or into the bottle's neck or body region. At its lower end the probe forms a probe contact and is at the same time configured as a gas tube with a gas channel which is open above the probe contact by radial openings.

The task of the invention is to provide a method for the pressure-filling of bottles or similar containers which among other things makes it possible to reduce the total duration of the particular filling process while maintaining high operational reliability. A method according to patent claim 1 is configured to resolve this object. A filling element for pressure-filling of bottles or similar containers is the subject-matter of claim 8 or 12.

The inventive method is executed as a pressure-filling method in which the inert gas or CO2 gas which the inflowing filling material displaces out of the respective container during filling/the filling phase is discharged through a return gas tube extending into the container, where at the end of the filling phase the filling material rises in the return gas tube while the liquid valve is still open. The probe provided or configured in the return gas tube effects, either immediately or with a preselected delay, a closing of the liquid valve as soon as the filling material rising in the return gas tube reaches the probe or the probe's response level. This response level is equal to the equilibrium level for example. However the probe's response level is preferably lower than the equilibrium level so that a closing of the liquid valve is effected or initiated before the filling material rising in the return gas tube reaches the equilibrium level.

For the purpose of the invention the expression “essentially” means variations from the respective exact value by +/−10%, preferably by +/−5%. Further embodiments, advantages and possible applications of the invention arise out of the following description of embodiments and out of the figures. All of the described and/or pictorially represented attributes whether alone or in any desired combination are fundamentally the subject matter of the invention independently of their synopsis in the claims or a retroactive application thereof. The content of the claims is also made an integral part of the description.

The invention is explained in detail below through the use of an embodiment example with reference to the figures. In the figures:

FIG. 1 shows in simplified representation a filling element of a filling system or of a filling machine for the pressure-filling of bottles with a liquid filling material, together with a bottle that is raised or pressed in sealed position against the filling element;

FIGS. 2 and 3 each show details of the filling element in enlarged representation.

In the figures, 1 is a filling element of a filling system or of a filling machine provided with a plurality of filling elements of the same type on the periphery of a rotor 2 that can be driven to rotate about a vertical machine axis.

Filling element 1 is used for the pressure-filling of bottles 3 or other containers with a liquid filling material and for this purpose—at least during a pre-tensioning phase and a filling phase of the filling process—the bottle mouth 3.1 is pressed in a sealed position against filling element 1 by a container carrier 4 which is located beneath filling element 1 and on which in the depicted embodiment respective bottle 3 stands upright with its bottle base, in the manner described more fully hereinbelow.

Filling element 1 comprises a [sic] in the depicted embodiment a filling element housing 5 in which is configured among other things a liquid channel 6 that is connected by its upper end via a pipe 7 to an annular tank 8 which is provided for all filling elements 1 of the filling system or filling machine in common and is partially filled in a level-controlled manner during the filling operation with the liquid filling material, so that there are formed in annular tank 8 an upper gas space 8.1 occupied by the gas (CO₂ gas) with the filling pressure considerably above the normal or ambient pressure, and a lower liquid space 8.2 to which filling elements 1 are connected via respective pipe 7. The filling material surface in tank 8 is on level N1. In the depicted embodiment, filling elements 1 are provided on the radially outward side of annular tank 8 relative to the vertical machine axis, by which inter alia an optimal positioning of filling elements 1 as well as a simplified maintenance cleaning are possible.

Liquid channel 6 forms annular discharge opening 9 for the filling material on the underside of housing 5. There is further provided on the underside of filling element housing 5 a ring seal 10 which encloses discharge opening 9 and is part of a centering tulip 11 which can be raised and lowered by a short stroke in the direction of the vertical filling element axis FA for centering respective bottle 3 and against which respective bottle 3 is pressed by its bottle mouth 3.1 at least during a pre-tensioning phase and a filling phase, with its bottle axis disposed on the same axis as filling element axis FA.

In liquid channel 6 there is provided a liquid valve 12 which can be opened and closed in a controlled manner and is formed essentially by a valve body 13 that interacts with an annular valve seat 14 which concentrically encloses filling element axis FA and is configured on the inner surface of liquid channel 6.

In the depicted embodiment, valve body 13 is provided on a return gas tube 15 which also acts as a valve stem and which can be moved up and down in a controlled manner through a predetermined stroke on filling element axis FA by way of an actuating device 16 for opening and closing liquid valve 12 together with valve body 13. The figures depict liquid valve 12 in its closed state. By an appropriate design of valve body 13 and of the inner surface of liquid channel 6 in the region of valve seat 14, the forming of a siphon-like gas seal is achieved there when liquid valve 12 is open.

Return gas tube 15 which is also disposed on the same axis as filling element axis FA extends with its lower return gas tube end 15.1 beyond the underside of filling element 1 and so protrudes by a length of that end into respective bottle 3 located in sealed position with filling element 1, at least during the pre-tensioning phase and the filling phase. Return gas tube 15 forms a return gas channel 17 that is open at the lower return gas tube end 15.1 and at the upper end discharges into a gas space 18 formed in filling element housing 5 (especially FIG. 3). The level of return gas tube end 15.1 or of the local opening of return gas channel 17 is labelled N2 and lies below level N1.

In gas tube 15 there is provided a probe 19 which is disposed on the same axis as filling element axis FA, which responds to the liquid filling material and which when for example the lower probe end 19.1 is wetted by the filling material delivers or initiates an electrical signal causing liquid valve 12 to close, for example by changing the electrical properties of probe 19 or at least of a measuring circuit formed between electrodes of probe 19. The level of this measuring circuit (response level of probe 19) is labelled N3 and lies below level N1. In the region of probe 19, return gas channel 17 is configured as a ring channel between the inner surface of return gas tube 15 and the outer surface of probe 19. As the figures also show, the lower probe end 19.1 inside return gas tube 15 is arranged at a distance from lower return gas tube end 15.1 so that response level N3 is not only above level N2 but in the depicted embodiment also above liquid valve 12 and valve seat 14.

In filling element housing 5 there are moreover configured several controlled gas paths with, in the depicted embodiment, a gas path exhibiting control valve 20 and which when control valve 20 is open connects gas space 18 to a ring channel 21 provided on rotor 2 for all filling elements 1 of the filling system in common, said ring channel 21 being in turn connected by a pipe 22 to gas space 8.1 of tank 8 and so carrying the inert gas at the pre-tensioning and filling pressure.

In the depicted embodiment, the gas path which includes control valve 20 comprises in detail two gas channels 20.1 and 20.2, of which channel 20.1 connects control valve 20 with gas space 18 and gas channel 20.2 connects control valve 20 with ring channel 21. In gas channel 20.2 there is provided a one-way restrictor 23, i.e. a combined throttle valve/check valve, which is constructed so that when control valve 20 is open an unthrottled gas flow out of ring channel 21 through gas channels 20.2 and 20.1 into gas space 18 is possible, i.e. the throttle of one-way restrictor 23 is not active, whereas the throttle of one-way restrictor 23 is fully active when gas flows in the opposite flow direction.

In a depicted embodiment there are provided in filling element housing 5 two further controllable gas paths exhibiting common control valve 24 and which when control valve 24 is open connect liquid channel 6 in the region of discharge opening 9 and in flow direction of the liquid filling material to liquid valve 12 with gas space 18 and also in a throttled manner to a further ring channel 25 provided on rotor 2 for all filling elements 1 of the filling system or filling machine in common, said ring channel 25 serving during the operation of the filling machine as a return gas ring channel and carrying return gas at normal or ambient pressure or at a pressure slightly above normal and ambient pressure, for example in the range from 0 to 1.5 bar.

The controllable gas path formed by control valve 24 comprises in detail three gas channels configured in filling element housing 5, namely gas channel 24.1 that connects liquid channel 6 in the region of discharge opening 9 to control valve 24, gas channel 24.2 that connects control valve 24 to gas space 8 and gas channel 24.3 that connects control valve 24 to ring channel 25. In gas channel 24.3 there are provided a throttle 26 and a check valve 27, the latter of which opens for a gas flow from gas channel 24.3 into ring channel 25 and closes for a gas flow in the opposite direction, so preventing a return flow of return gas from ring channel 25 into gas channels 24.1-24.3 when control valve 24 is open. Control valves 20 and 24 are depicted in their closed, non-activated state.

In the depicted embodiment, actuating device 16 and control valves 20 and 24 are pneumatically confirmed [sic] by electrical control valves (not shown) of an electronic control device (also not shown) of the filling system or filling machine, to which (control device) the signal of probe 19 is also fed.

With filling element 1 it is possible for example to pressure-fill bottles 3 with the liquid filling material from annular tank 8 in the follow manner:

Bottle 3 that is to be filled and which stands upright with its base on container carrier 4 and with its bottle axis aligned in the direction of filling element axis FA is raised with container carrier 4 so that the bottle now lies with its bottle mouth 3.1 against the ring seal but an annular gap to the surroundings is left in the region of bottle mouth 3.1 and return gas tube 15 extends by its lower return gas tube end 15.1 into bottle 3.

In this state, in a first process step (purging phase) of the filling process, the interior of bottle 3 is purged with CO2 gas in order to remove the air present in the bottle as completely as possible. To this end, with liquid valve 12 closed and control valve 20 open, CO2 gas from ring channel 21 is introduced or blown across gas space 18 and return gas channel 17 into the interior of bottle 3 so that the air originally present in bottle 3 is displaced out of the bottle interior through the so-called annular gap.

In a further process step (pre-tensioning phase) of the filing process, bottle 3 is raised into sealed position against filling element 1 so that ring seal 10 establishes a tight connection between discharge opening 9 and in the interior of bottle 3 [sic]. For the pre-tensioning, while liquid valve 12 is still closed, the control valve is opened so that CO2 gas under pressure can flow through open control valve 20, gas space 18 and gas channel 17 into the interior of bottle 3 and the bottle interior is pre-tensioned to the pre-tensioning and filling pressure.

In both the purging phase and pre-tensioning phase, the throttle of one-way restrictor 23 is not effective, so that an unrestricted gas flow out of ring channel 21 into bottle 3 is possible and among other things the cycle times for the purging phase and the pre-tensioning phase are thereby reduced, so increasing the output of the filling system or filling machine (number of filled bottles 3 per unit of time).

During the subsequent filling phase which is initiated by opening liquid valve 12, respective bottle 3 is still in sealed position against filling element 1. At least a rapid filling of bottle 3 is effected during the filling phase while control valve 20 is also open, as a result of which the CO2 gas which is displaced from the bottle interior by the filling material flowing into bottle 3 through discharge opening 9, can flow back into ring channel 21 through return gas channel 17, gas space 18 and open control valve 20. The speed at which the liquid filling material flows into bottle 3 is determined among others things by level N1. To achieve a defined filling speed, during the filling phase the gas path for the CO2 gas displaced from bottle 3 into ring channel 21 is restricted by the throttle of one-way restrictor 23 and which is effective in this direction of flow. One-way restrictor 23 therefore does justice to the different requirements when purging and pre-tensioning on the one hand and when pressure-filling on the other without the need for an additional control valve and without any attendant constructional and/or technical control effort.

When filling material surface 3 reaches level N2, lower return gas tube end 15.1 is immersed in the filling material such that the CO2 gas left in the head region of bottle 3, i.e. in the region between the filling material surface in bottle 3 and open liquid valve 12 and/or the gas seal there formed, cannot now flow into return gas channel 17, the liquid filling material in this return gas channel 17 rising instead. If probe 19 were not present, the filling material surface in the return gas channel would reach the equilibrium level which because of the gas seal of the open liquid valve and the CO2 gas trapped in the head space of bottle 3 lies below level N1 but above response level N3 of probe 19. What probe 19 now achieves is that a probe-controlled closing of liquid valve 12 is initiated when the filling material rising in return gas channel 17 has already reached response level N3, i.e. liquid valve 12 does not close only when a predetermined period of time has elapsed or only when a predetermined angular position of rotor 2 of the filling machine is attained, as is the case with previously known filling systems of the type in question for the pressure-filling of containers.

The closing of control valve 20 and opening of control valve 24 is preferably also initiated by the signal of probe 19 which brings about the closing of liquid valve 12, so that through open control valve 24 there is effected a relieving of pressure in the head space of bottle 3 that is still in sealed position with filling element 1 into ring channel 25 as well as an emptying of return gas channel 17 or return flow of the filling material out of return gas channel 17 into the bottle, this being due to the connection between gas space 18 and the region of discharge opening 9 over gas channels 24.1 and 24.2. A return flow of return gas from ring channel 25 into the head space of bottle 3 is effectively prevented by check valve 27.

The filling process is ended by filled bottle 3 with container carrier 4 being lowered until return gas tube 15 is completely withdrawn from bottle 3. Filled bottle 3 can now be removed from container carrier 4 and passed to a machine for sealing, for example.

During the operation of the filling system or filling machine, CO2 gas is continuously withdrawn from ring channel 21 in particular for purging and is replenished through pipe 22 from gas space 8.1 of annular tank 8 so that despite the CO2 gas being returned to ring channel 21 during the filling phase, no CO2 gas and in particular no CO2 gas contaminated with air passes from ring channel 21 into gas space 8.1 of tank 8. In tank 8, pure CO2 gas is therefore always present at the phase boundary with the filling material.

The described filling element 1 has considerable advantages:

Independently of probe 19, an accelerated purging and pre-tensioning of respective bottle 3 with an unrestricted CO2 gas flow and at the same time during the filling phase a restricted return gas flow for an optimum and repeatable filling speed are achieved by one-way restrictor 23 provided in gas channel 20.2.

Probe 19 arranged in return gas tube 5 brings about a closing of liquid valve 12 before the normal state of equilibrium has occurred or the level of the liquid filling material in the return gas channel 17 has risen to the level corresponding to this state of equilibrium. Probe 19 therefore limits the rise of filling material in return gas tube 15.

This creates the possibility of reducing the total duration of the filling process/increasing the output of a filling machine (number of filled bottles 3 per unit of time) by for example a central control unit or central processor of the filling machine measuring the time to the response of probe 19 separately for all filling elements 1 and then controlling the speed of the filling machine so that even at the “slowest” filling element 1 of the filling machine the filling process is reliably completed before respective bottle 3 is lowered by that filling element with container carrier 4.

The amount of filling material rising in return gas channel 17 and hence the amount of filling material returned to respective bottle 3 can also be kept small by appropriate selection of level N3, i.e. by an appropriate approximating of level N3 to level N2.

The closing of liquid valve 12 after probe 19 responds also avoids filling material continuing to flow from liquid channel 6 into bottle 3 as a result of vibrations of the filling system or filling machine as is the case with known filling systems for pressure-filling of containers or bottles which (filling systems) do not exhibit probe 19.

Through the triggering of control valves 20 and 24 and in particular the opening of control valve 24 on the basis of the signal from probe 19, after the closing of liquid valve 12 there is effected an early pressure relief both of the head space of bottle 3 and of return gas channel 17 across throttle 26 as well as an emptying of return gas channel 17, so that an abrupt emptying (expansion pulse) of return gas channel 17 into the filling material surface of filled bottle 3 and an associated froth over of the filling material in bottle 3 does not occur when bottle 3 is pulled off or lowered down from filling element 1. The early emptying of return gas tube 15 also avoids filling material residues remaining in gas tube 15 during or after the lowering down of bottle 3 from filling element 1, which contributes overall to reducing the total duration of the filling process and hence to increasing the output of the filling machine, in particular also when the filling material is carbonated and prone to frothing.

By using probe 19 it is also basically possible to dispense with the gas seal in the region of liquid valve 12.

A further advantage is that with the responding of probe 19 and the closing of liquid valve 12 which this brings about, when the desired fill height is reached the connection between annular tank 8 and respective bottle 3 is immediately interrupted so that even fill height fluctuations in bottles 3 that are caused by pressure variations in gas space 8.1 and variations in level N1 are effectively avoided.

Because the head space of respective bottle 3 is also connected via control valve 24 to gas space 18 or to the upper end of return gas tube 17 after liquid valve 12 closes, it is also basically possible to pull filled bottle 3 from filling element 1 while there is still some slight positive pressure in the bottle without there being an abrupt discharge of filling material present in return gas tube 17 or frothing in bottle 3, among other things in order to reduce the overall duration of the filling process and to increase the output of the filling system or filling machine.

A further essential advantage consists in the fact that for filling element 1, despite the many advantages without fundamental structural alterations, it is possible to use for example a design already tried and tested with filling systems or single-chamber filling systems for the pressure-filling von containers.

The invention has been described hereinbefore by reference to one embodiment. It goes without saying that numerous variations as well as modifications are possible without departing from the inventive concept underlying the invention.

There is also the basic possibility for example for liquid valve 12 to close with a certain time delay after probe 19 responds in order to achieve a fill height correction in this way.

LIST OF REFERENCE SIGNS

-   1 Filling element -   2 Rotor -   3 Bottle -   3.1 Bottle mouth -   4 Container carrier or bottle plate -   5 Filling element housing -   6 Liquid channel -   7 Product or filling material pipe -   8 Annular tank -   8.1 Gas space of annular tank 8 -   8.2 Liquid space of annular tank 8 -   9 Annular discharge opening -   10 Ring seal -   11 Centering tulip -   12 Liquid valve -   13 Valve body -   14 Valve seat -   15 Return gas tube -   15.1 Lower return gas tube end -   16 Actuating device for liquid valve 12 -   17 Return gas channel -   18 Gas space -   19 Probe -   19.1 Lower probe end -   20 Control valve -   20.1, 20.2 Gas channel -   21 Ring channel -   22 Pipe -   23 One-way restrictor -   24 Control valve -   24.1, 24.2, 24.3 Gas channel -   25 Ring channel on rotor 2 -   26 Throttle -   27 Check valve -   N1 Level of the filling material surface in the annular tank 8 -   N2 Level of the lower end of the return gas tube 15.1 -   N3 Response level of probe 19 -   FA Filling element axis 

1-12. (canceled)
 13. A method for pressure-filling containers with a filling material using a single-chamber filling system having a filling element that, in a filling element housing, exhibits a liquid channel having a liquid valve, said liquid channel being connected, in a direction of flow of said filling material upstream of said liquid valve, to a liquid space of a filling material tank that is partly filled with said filling material and that is maintained at a pre-tensioning or filling pressure and wherein, in a direction of flow of said filling material downstream of said liquid valve, said filling material tank forms a discharge opening against which a container is arranged with a container opening thereof in sealed position, at least during filling thereof, and wherein said filling material tank comprises a return gas tube that extends into said container during filling thereof and through which, during filling, inert gas displaced from said container, which is pre-tensioned with an inert gas, is returned into one of a manifold carrying said inert gas at said pre-tensioning or filling pressure, and a gas space of said filling material tank, and in which, after immersiom of a lower return gas tube end of said return gas tube into a filling-material surface rising in said container, said filling material rises to a level at which further filling of said container with the filling material is ended, said method comprising effecting further filling of said container, wherein effecting further filling of said container comprises providing a probe disposed or configured in a return gas channel, said probe being configured to generate a probe signal as soon as said filling material, which rises in said return gas channel, reaches a response level of said probe, and responding to said probe signal by closing said liquid valve.
 14. The method of claim 13, further comprising limiting, by said probe, rise of said filling material in said gas channel.
 15. The method of claim 13, further comprising selecting said response level of said probe to be above a level of said lower return gas tube end and below a level up to which, in the absence of closing said liquid valve in response to said probe signal, said liquid filling material would rise in said return gas channel before reaching an equilibrium state thereof.
 16. The method of claim 13, further comprising inserting said probe into said return gas tube or a return gas channel thereof, said probe being a rod-shaped probe comprising one of at least one probe contact and at least one electrical measuring circuit for responding to liquid filling material disposed in a region of a lower probe end thereof.
 17. The method of claim 13, wherein after filling, said container has a head space that remains unoccupied by said filling material, and wherein responding to said probe signal further comprises causing a simultaneous reduction in pressure in said head space down to a pressure less than said filling pressure to prevent at least one of expansion pulses of said filling material into a surface of said filling material surface in said container and filling-material residues in said return gas tube after said container, which has been filled, is removed from said filling element.
 18. The method of claim 13, wherein after filling, said container has a head space that remains unoccupied by said filling material, and wherein responding to said probe signal further comprises emptying said gas tube by creating a gas connection between said head space and an end of said or gas channel facing away from said container to prevent at least one of expansion pulses of said filling material into a surface of said filling material surface in said container and filling-material residues in said return gas tube after said container, which has been filled, is removed from said filling element.
 19. The method of claim 13, further comprising providing a siphon-like gas seal in a region of said liquid valve when said liquid valve is open.
 20. The method of claim 13, further comprising regulating an output of one of said filling element and a filling machine comprising a plurality of filling elements as a function of said probe signal.
 21. An apparatus comprising a filling element for pressure-filling containers with a filling material, said filling element comprising at least one liquid channel configured in a filling element housing, at least one liquid valve in said at least one liquid channel said at least one liquid channel being connected, in a direction of flow of said filling material upstream of said at least one liquid valve, to a liquid space of a filling material tank that is partly filled with filling material and maintained at a pre-tensioning or filling pressure, said at least one liquid channel forming, in said direction of flow of said filling material, downstream of said at least one liquid valve, at least one discharge opening against which a container is arranged by a container opening in sealed position at least during filling thereof, and having a return gas tube extending into said container during filling thereof through which, during filling, inert gas displaced from said container, which is pre-tensioned with an inert gas, is returned into one of a manifold carrying said insert gas at pre-tensioning or filling pressure and a gas space of said filling material tank and in which, after immersing of a lower return gas tube end of said return gas tube into a filling-material surface rising in said container, said filling material rises to a level at which further filling of said container with said filling material is ended, and a probe arranged or configured in said return gas channel, said probe being configured to generate a probe signal to cause closing of said liquid valve as soon as said filling material, which is rising in said return gas channel, reaches a response level of said probe.
 22. The apparatus of claim 21, wherein said probe is a rod-shaped probe inserted into one of said return gas tube and a return gas channel thereof, said probe comprising one of at least one probe contact and at least one electrical measuring circuit, said one of at least one probe contact and at least one electrical measuring circuit being configured to respond to said liquid filling material in a region of a lower probe end.
 23. The apparatus of claim 21, further comprising a gas seal provided or configured at least in a region of said liquid valve when said liquid valve is open.
 24. The apparatus of claim 21, further comprising, in a controlled gas path that is configured in said filling element, and through which at least a pre-tensioning of a container located in sealed position with said filling element and a return of the inert gas displaced from the container during filling takes place, a one-way restrictor unit which through said controlled gas path brings about an unrestricted inert gas flow for pre-tensioning and a restricted inert gas flow when filling. 